Robotic Welding of Small Parts with a FANUC Cobot
Context
problem
When welding small parts with simple geometry, the main challenge is not the shape but takt time and repeatability. The client SL Industries Ltd. (Ruse, Bulgaria) produces parts for hydraulic grippers, where electro-rivets are welded onto the component. The manual process is relatively slow, requires constant concentration, and makes it difficult to maintain a stable takt time at higher volumes. Every small variation in execution affects quality and leads to additional inspection. A more efficient and reliable welding method is needed – one that ensures high repeatability, operator safety, and the potential to further develop the process over time.
Approach
Solution
Bullitt Robotics developed a compact robotic welding system with a FANUC collaborative robot, tailored to the needs of SL Industries. The robot welds electro-rivets onto parts for hydraulic grippers, operating on two stations. While welding is performed on one station, the operator safely prepares the next parts on the other. The combination of the FANUC cobot and a Fronius welding power source provides a high level of integration and precise parameter control. Thanks to easy programming and safe human–robot collaboration, the system achieves an almost continuous process and significantly higher productivity.
Almost continuous welding process
Two-station operation allows the robot to weld on one side while the operator loads parts on the other, minimising idle time and delivering roughly double the productivity.
High repeatability and quality control
The FANUC cobot and Fronius power source ensure stable parameters and consistent execution of every weld. This repeatability enables systematic optimisation and sustained high quality.
Simplified programming and safe collaboration
The collaborative platform enables fast, intuitive programming and safe cooperation between operator and robot. This lowers the barrier to adoption and makes the system easier to adapt over time.
Technical specifications
Compact collaborative welding system
The system for SL Industries is designed for automated welding of small parts with high repeatability and safe human–robot interaction. Key technical specifications include:
| Characteristic | Description |
|---|---|
| Client | SL Industries Ltd., Ruse, Bulgaria |
| Completion date | March 2025 |
| Main components | FANUC collaborative robot, Fronius welding power source, two-station work cell |
| Welding operations | Welding of electro-rivets onto parts for hydraulic grippers |
| Welding time | Optimised for an almost continuous process thanks to two-station operation |
| Control | Intuitive programming and operation of the collaborative robot by the operator |
| Part fixturing | Special fixtures for securing small parts with high repeatability |
| Work cycle | Alternating welding and loading on two stations for roughly double the productivity compared to a manual process |
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